AEROSPACE APPLICATIONS A613G - Mitsubishi Materials€¦ · AEROSPACE AIR FRAME 5 6 7 10 12 13 14 15 16 17 11 8 9 y CFRP y CFRP/AI y CFRP/Ti Tool Page y Precipitation Hardening Stainless

APPLICATIONSAEROSPACE

A613G

2

INDEXAEROSPACE

AIR FRAME567

10

12131415

1617

11

89

PageTooly CFRP y CFRP/AI y CFRP/Ti

y Precipitation Hardening Stainless Steel

Drilling

Drilling

Trimming

Face Milling, Pocket Milling




Rough Pocket Milling

Drilling

Side Milling, Rough Pocket Milling

Face Milling, Side Milling

Side Milling, Pocket Milling

y Titanium Alloy

y Aluminium Alloy y Aluminium-lithium Alloy

MCC Drill

MCA Drill

DFC End Mill

AXD Series

AXD Series

ALIMASTER

VFX Series

AJX Series

APX Series

MMS Drill

Coolstar Series

Exchangeable Head End MillsiMX Series

Side Milling, Pocket Milling ARP Series

3

ENGINE

LANDING GEAR

PageTool

19202122

3233343536

23

2524

26

39

27

28

2930

Copy Turning

External, Face and Internal Turning




Machining of Upper Surface of Protuberance

Drilling

Drilling

Drilling (Helical), Profi le Milling

Finish Profi le Milling


Rough Milling

Finish Pocket Milling




y Ni-based Superalloy

y Titanium Alloy

y Titanium-aluminium Alloy

y Maraging Steel

y Titanium Alloy

GY Series

APX Series

VFX Series

APX Series

ARX/ARP Series

SMART MIRACLEVibration Control ball nose end mill

SMART MIRACLEVibration Control ball nose end mill

SMART MIRACLEEnd mill Series

MMS Drill

MNS Drill



LS/MS/RSMP9005/MP9015/MT9015

US905

LS/MS/RSMT9015

FJ/MS/GJVP05RT/VP10RT

External, Face and Internal Turning JT Holder

Drilling (Helical), Profi le Milling CERAMIC End Mill

4

Air Frame

5

MCC MCC

MCC A

MCC B

0 200 400 600 800 1000 1200 1400 1600

Key Point on Machininga A 90°point angle is used to reduce thrust when drilling, this prevents

delamination and also improves hole tolerance.

Drill ø 6.55Cutting Speed vc120 m/min (n5840 min-1)Feed f0.10 mm/revMachine Vertical type M/CCoolant Dry cutting

DrillingMCC Drill(Leafl et P713G)

AIR FRAMEWork Materials [CFRP]

Application Example

New CVD diamond coated drills

Optimized cutting geometry

306 holes 588 holes MCC(1192 holes)Conventional Conventional

Entrance

Exit

<Cutting condition>Tool : ø6.55 Work material : CFRP　 For tool life (10mm) For hole quality (12.5mm)

Cutting speed : 120m/minFeed : 0.10mm/revCutting mode : Dry cutting

Conventional

Comparison of Tool Life and Hole (Entrance/Exit)

Conventional

*The tool life determination depends on the chipping After 820 holes machining

Can continue

Chipping

(Holes)

1.6 times longer tool life

6

-40

-20

0

20

40

60

80

100

1 50 100 150 200 250

(μm) (μm)

-40

-20

0

20

40

60

80

100

1 5

MCA

CFRP

Al

CFRP

Al

Drill ø 6.38Work Material CFRP + Aluminium AlloyCutting Speed vc100 m/min (n5000 min-1)Feed f0.15 mm/revMachine Vertical type M/CCoolant Internal air

Drilling

AIR FRAMEWork Materials [CFRP, CFRP/Al]

Key Point on Machininga A unique flute design is employed to prevent the aluminium chips from

damaging the finish of the CFRP section thus reducing the gap in hole size between the aluminium and CFRP section.

Application Example

New CVD diamond coated drills

Unique groove design

Groove Shape Effect

MCA Drill(Leafl et P713G)

<Cutting condition>Tool : 0.251”(ø6.38) Work material : CFRP(11mm)+Al(5mm)

CFRPCutting speed : 100m/minFeed : 0.15mm/rev

AlCutting speed : 100m/minFeed : 0.15mm/revCutting mode : Internal air

*Enlarged view

*Hatching: Required hole precision

Back Counter Occurrence

(Holes) (Holes)

Outside the hole tolerance standards (5 holes)

X Entrance (CFRP)Y Entrance (CFRP)

X Entrance (CFRP)Y Entrance (CFRP)

X Center (CFRP)Y Center (CFRP)

X Center (CFRP)Y Center (CFRP)

X Exit (Al)Y Exit (Al)

X Exit (Al)Y Exit (Al)

Conventional

7

DFC4JCD1000

DFC4JCD1000 (ø10)CFRPn6000min-1

(vc188m/min)vf750mm/min(fz0.03mm/tooth)ap5mm

DFC4JCD1200 (ø12)CFRPn2390min-1

(vc90m/min)vf382mm/min(fz0.04mm/tooth)ap18mm, ae2.0mm & 0.5mm

30.31 mmø25.4 mm→ø30.4 mm

End millWork Material

Revolution

Feed

Depth of CutCoolant Air blow

End millWork Material

Revolution

Feed

Depth of CutCoolant Air blow

Conventional

Cutting direction

Cutting direction

Trimming

DFC End mill(TOOLS NEWS B189G)

New CVD diamond coated end mills

Optimized cutting geometry

AIR FRAMEWork Materials [CFRP]

Key Point on Machininga Tool life is generally short due to the high strength of the carbon fibres, and

also due to the fact that delamination and burrs develop easily. Therefore the DFC end mill range employs a CVD diamond coating and a cutting edge geometry that prevents these problems and prolongs tool life.

Application Examplea The combination of the CVD coating and the

cutting edge prevents problems relating to burrs and delamination.

No burr formation

Burr formation

Flank wear after 96 holes

machining

Can continue

Tool

96 Holes

Trimming Hole Expansion

Machining path

8

Holder AXD7000R05003A-H63AInsert (Grade) XDGX227030PDFR-GL (TF15)Work Material A7075Cutting Speed vc2830 m/min (n18000 min-1)Feed fz0.21 mm/tooth (vf11340 mm/min)Depth of Cut ap18 mm, ae50 mmCoolant Emulsion

ae50mm

ap18mm

AXD Series(TOOLS NEWS B116G)


Low cutting resistance

Convex cutting edge

Helical fl ank

AIR FRAMEWork Materials [Aluminium Alloy]

Key Point on Machininga Machining of these kinds of components means machining from block,

whereas much as 90% of the material needs to be removed. As such it is necessary to carry this out as fast and efficiently as possible. The AXD series uses inserts that have a suitable relief that results in lower cutting resistance. Also a convex cutting edge is used to improve the overall chip disposal. The combination of which result in the tool to be able to be used for high speed and high efficiency machining.

Application Examplea Metal removal rate of 10,000cm3/min can be

achieved when using the AXD7000-HSK.

Avoids poor wall surface finishes because the tool is designed to interpolate corners of the pocket, thereby also preventing vibration.

Point

9

320 1

GM breaker(MP9120)

Holder AXD4000-050A04RAInsert (Grade) XDGX175024PDER-GM (MP9120)Work Material Aluminium-lithium AlloyCutting Speed vc4712 m/min (n30000 min-1)Feed fz0.1 mm/tooth (vf12000 mm/min)Depth of Cut ap6 mm, ae50 mmCoolant Emulsion

AXD Series(TOOLS NEWS B116G)


Low cutting resistance

Convex cutting edge

Helical fl ank

AIR FRAMEWork Materials [Aluminium-lithium Alloy]

Key Point on Machininga For higher cutting speed ranges the use of the MP9120 is recommended.

Application Examplea For the machining of Aluminium-lithium alloys the GM

breaker in combination with the tool grade MP9120 is recommended. This results in reduced chipping and stable machining.

GM Breaker

Tool life (Number of work pieces)

Conventional 3 times

10

End mill CSRARBD2500R300 (ø 25/R3)Work Material A7075Cutting Speed vc1178 m/min (n15000 min-1)Feed fz0.22 mm/tooth (vf10000 mm/min)Depth of Cut ap25 mm, ae20 mmCoolant Emulsion

Avoids poor wall surface finishes because the tool is designed to interpolate corners of the pocket, thereby also preventing vibration.

15000min-1/75kW, BT50

ae20mm

ap25mm

ALIMASTER(TOOLS NEWS B118G)

Face Milling, Pocket Milling Improved chip removal

Chip fl ow Chip fl ow

Instability in chip separation

Smooth chip separation


Key Point on Machininga The ALIMASTER series employs a unique cross section geometry that

enables effective chip removal properties. The overall result of which is that it can be used to machine with higher speeds and increased efficiency.

Application Examplea Metal removal rate of 5,000cm3/min can be

achieved when used on machines with sufficient power.

<Machine specifi cation>

Competitor Mitsubishi

Point

11

0 50 100 150



High Precision

High Rigidity

Low CostExchangeable Head End Mills

iMX Series(TOOLS NEWS B200G)

Head (Grade) IMX10S3A10008 (ET2020)Holder IMX10-U10N014L070COverhang length 35 mmWork Material A7075Cutting Speed vc408 m/min (n13000 min-1)Feed fz0.12 mm/tooth (vf4680 mm/min)Depth of Cut ap5 mm, ae10 mmCoolant Emulsion

Key Point on Machininga The iMX exchangeable heads specific for machining aluminium alloys

employs a large rake angle and polished cutting edges to result in a sharper cutting edge to reduce cutting resistance and to prevent problems relating to welding.

Application Examplea When the iMX head is used with a carbide arbor

this results is high rigidity and prevents vibration even when carrying out slotting applications.

iMX

Conventional

Bottom face

Bottom face

Wall surface

Wall surface1.5 times

Effi ciency (%)

12

0 50 100 150

Holder VFX6-063A04A060RInsert (Grade) XNMU190912R-LS (MP9130)Work Material Ti-6Al-4VCutting Speed vc55 m/min (n280 min-1)Feed fz0.12 mm/tooth (vf135 mm/min)Depth of Cut ap25-60 mm, ae10-45 mmCoolant Emulsion (10 MPa)

VFX Series(TOOLS NEWS B182G)

Cutting force

AIR FRAMEWork Materials [Titanium Alloy]

Key Point on Machininga When rough machining of titanium alloys problems such as chipping and

abnormal damage can occur if using tools with low rigidity. The VFX series offers a design that has high rigidity and also insert geometry that employs a convex cutting edge to improve cutting edge stability.

Application Examplea When used with a high pressure internal coolant

system efficiency can be increased by up to 150%.

VFX

Conventional Over 1.5 times

Arranging the inserts vertically

Convex curvecutting edge

V formation of the clamping face

Effi ciency (%)

Side Milling, Rough Pocket Milling

13

AJX12R322SA32SJDMT120423ZDER-JL (MP9130)Ti-6Al-4Vvc50 m/min (n500 min-1)fz0.6 mm/tooth (vf600 mm/min)ap1 mm, ae20-32 mm

320 1

AJX(MP9130)

*Graphical representation

Multi-layering of the coating prevents cracks penetrating through to the substrate.

New coated grade with

superior fracture resistance

Face Milling, Side Milling

HolderInsert (Grade)Work MaterialCutting SpeedFeedDepth of CutCoolant Emulsion

Work Materials [Titanium Alloy]

Key Point on Machininga When machining materials such as titanium alloys cutting resistance varies

and as such the chips generated are saw-tooth type. This can result in chipping of the cutting edge when high feed roughing applications. To prevent this kind of problem from occurring the JL breaker, that has a sharp cutting edge to reduce overall cutting resistance and a newly developed multi-layered coating, MP9130 is employed. This combination leads to the ability for stable high feed roughing applications.

Application Examplea Possible to achieve 1.5 times longer tool life due

the reduced cutting edge chipping.

AIR FRAME


Conventional

AJX Series(TOOLS NEWS B028G)

1.5 times

14

0 13.1 26.2 39.3 52.4 65.4 78.5

ARP

0.00

0.05

0.10

0.15

0.20

0.25

VB

(mm

)

ARP : VB=0.110 mm

Work Materials [Titanium Alloy]

ARP(TOOLS NEWS B222G)


3 types of breakers

AIR FRAME

Holder ARP5PR3204SA32MInsert (Grade) RPHT1040M0E4-L (MP9130)Work Material Ti-6Al-4VCutting Speed vc50 m/minFeed fz0.1 mm/toothHole Depth ap2.5 mm ae25 mmCoolant Emulsion

Key Point on Machininga When rough machining of titanium alloys due to the type of chips generated

problems relating to chipping and fracturing are common. The ARP series inserts are available in 3 breaker geometries and with the new MP9130 tool grade. This combination results in stable machining when carrying out roughing and finishing application of titanium alloys.

Application Examplea Due to the use of the MP9130 and the L breaker

tool life was improved by 25%.

Conventional

Cutting time (min)

Cutting Time: After 53 Minutes

Coolant nozzle

Conventional : VB=0.231 mm

Tool life extended by 25%

15

End mill VF6MHVCHD1600 (ø 16)Work Material Ti-6Al-4VCutting Speed vc150 m/min (n3000 min-1)Feed fz0.1 mm/tooth (vf1800 mm/min)Depth of Cut ap24 mm, ae1.6 mm (Trochoid)Coolant Emulsion (0.7 MPa)

Titanium alloy

21mm

1.6m

m24

mmConventional

(External coolant)

Feed rate:1800mm/min (0.1mm/tooth)

Feed rate:1350mm/min (0.075mm/tooth)


Coolstar Series(TOOLS NEWS B171G)

VF6MHVCH

Excellent cooling effect

Multiple internal coolant holes

Unique fl ute geometry

AIR FRAMEWork Materials [Titanium Alloy]

Key Point on Machininga When machining titanium alloys due to the fact that the thermal conductivity

is low heat generated during machining localizes around the cutting edge. This results in welding problems and as such it is necessary to prevent heat generation and to remove the chips effectively. The Coolstar series is designed with multiple through coolant hole in the flutes of the tool. This ensures effective cooling and improves chip evacuation.

Application Examplea Due to the use of coolant through the flutes welding is

prevented and effective chip evacuation can be achieved.

Excellent chip

removal andcooling.

Adhesion

16

Holder (Shell type) APX4K-050A09A042RAInsert (Grade) AOMT184816PEER-H (MP9120)Work Material 15-5PHCutting Speed vc80 m/min (n510 min-1)Feed fz0.1 mm/tooth (vf80 mm/min)Depth of Cut ap35 mm, ae35 mmCoolant Emulsion

Work Materials [Precipitation Hardening Stainless Steel]

Key Point on Machininga 15-5PH is often used for components in the aerospace industry. It has high

strength and as such chipping and fracturing of the cutting edge can easily occur. The APX series has a number of insert geometries and coated tool grades to enable stable machining to be achieved.

Application Examplea When compared to a conventional product when using

the APX series with the newly developed MP9120 coated tool grade, efficiency was improved by 250%.

AIR FRAME

APX(MP9120)

Conventional 2.5 times

Effi ciency (%)

Rough Pocket MillingAPX Series

(TOOLS NEWS B055G)

Double-phased helical rake angles

Tough cutting edge (Convex curve)

High rigidity cutter body

Low cutting resistance insert

100500 150 200 250

17

Work Materials [Precipitation Hardening Stainless Steel]

Key Point on Machininga 15-5PH is often used for components in the aerospace industry. It has high

strength and as such chipping and fracturing of the cutting edge can easily occur. For drilling applications the MMS drill employs a suitable cutting edge geometry and coating to enable stable machining.

Application Examplea The end users target was 200 holes, however using

the MMS drill it was possible to drill up to 400 holes, double that of the original target.

AIR FRAME

MMS

User's target (Conventional

product)2 times

Tool life (hole)1000 200 300 400

DrillingMMS Drill

(TOOLS NEWS B180G)

“TRI-Cooling Technology”

Excellent cooling performance

Drill (Grade) MMS0800X3DB (DP7020)Work Material 15-5PH (42HRC)Cutting Speed vc100 m/min (n3980 min-1)Feed f0.2 mm/revHole Depth 24 mmCoolant Emulsion

18

Engine

19

MP9015 MP9005

0 35 70100 20 4030

Holder DCLNL3225P12Insert (Grade) CNMG120408-MS (MP9015)Work Material Inconel® 718Cutting Speed vc40 m/minFeed f0.2 mm/revDepth of Cut ap2 mmCoolant Emulsion

Holder DCLNL3225P12Insert (Grade) CNMG120408-LS (MP9005)Work Material Inconel® 625Cutting Speed vc50 m/minFeed f0.15 mm/revDepth of Cut ap0.5 mmCoolant Emulsion

2 times 2 times

External and Face and Internal Turning HSK-T Tools

(TOOLS NEWS B134G)LS/MS/RS

MP9005/MP9015/MT9015(TOOLS NEWS B214G)

Good cutting performance

ENGINEWork Materials [Ni-based Superalloy]

Key Point on Machining

Application Example

Conventional Conventional

Tool life (min) Tool life (min)

PSC Tools(Special support)

a The MP9000 coated tool grade series is available for low speed and medium rough machining applications of Ni based alloys.

a Based on the examples below, by employing the MP9000 series for low speed medium rough applications tool life was doubled compared to current tool grades.

20

Holder H63TH-PRDCN-H12Insert (Grade) RCMX1204M0 (US905)Work Material Inconel® 718Cutting Speed vc100 m/minFeed f0.15 mm/revDepth of Cut ap0.5 mmCoolant Emulsion

2.5 times

External and Face and Copy Turning HSK-T Tools

(TOOLS NEWS B134G)US905

(TOOLS NEWS B036G)




Application Examplea Based on the example below, by employing the US905

tool grade for high speed finishing applications tool life was increased by up to 2.5 times.

US905

Conventional

20 4 106 8

Tool life (min)

a US905 coated tool grade is available for high speed and medium finish machining applications of Ni based alloys.

21

Holder GYHL2525M00-M25LInsert (Grade) GY2M0600J030N-GS (VP10RT)Work Material WASPALOY®

Cutting Speed vc35 m/minFeed f0.05 mm/revDepth of Cut ap10 mmCoolant Emulsion

Further use is possible because of small wear. (after 25 min. machining)

MIRACLE® coating

Carbide substrate(HRA92.0)

VB: 0.122mm VP10RT

Copy Turning GY Series(TOOLS NEWS B140G)


BM Breaker(Medium feeds)

GS Breaker(Low feeds)


Key Point on Machininga When machining of Ni based alloys it is necessary to use a sharp edge to

reduce cutting resistance and overall heat generation. The GY series employs a number of geometries that offers a sharp edge to increase tool life.

Application Examplea Stable tool life was achieved when machining

WASPALOY®.

22

Holder APX3000-050A07RAInsert (Grade) AOMT123620PEER-M (MP9130)Work Material Inconel® 718Cutting Speed vc30 m/min (n190 min-1)Feed fz0.03 mm/tooth (vf40 mm/min)Depth of Cut ap1 mm, ae40 mmCoolant Emulsion

APX Series(TOOLS NEWS B055G)



Key Point on Machininga When machining exotic materials, like Ni-based alloys, due to the fact that the

thermal conductivity is low heat generated during machining localizes around the cutting edge that results in work hardening leading to premature tool failure. The APX series offers suitable insert geometries and tool grades to achieve stable machining and increase tool life.

Application Examplea Compared to a conventional product tool life was

doubled.

High rigidity cutter bodies

Low cutting resistance insertMachining of upper surface

of protuberance


Over 2 times

APX

Conventional

300 60

Tool life (min)

23

øDHødc

øD1

Holder ARX35R142SA12SInsert (Grade) RDMW0724M0E (VP15TF)Work Material Inconel® 718Cutting Speed vc30 m/minFeed f0.2 mm/rev (Helical Cutting)Hole Depth 20 mm (1 mm/rev), Hole dia. 25 mmCoolant Emulsion

y Helical Cuttinga Setting a tool's centre excursion

Tool's center excursion

Required bore diameter

Tool's cutting diameter

ødc = øDH - øD1

VB: 0.08mm

Drilling (Helical), Profile Milling ARX(TOOLS NEWS B066G)

ARP(TOOLS NEWS B222G)


Key Point on Machininga For the engine casing there are applications that require hole making on the

outside of the casing it is possible to use helical drilling to machine these holes. Additionally application may include profile milling.

Application Examplea By using a small diameter radius end mill it is

possible to machine large diameter holes via helical machining.

Multifunctional

Further use is possible because of small wear. (after 7 min. machining)

24

CE6SRB

CE6SRB

CE6SRB

800°C

0 10 20 30 40 50

Drilling (Helical), Profile Milling

CERAMIC End mill(TOOLS NEWS B228G)


Ni based difficult-to-cut heat resistant alloys such as Inconel® 718 soften at temperatures exceeding 800ºC. At these temperatures, difficult-to-cut materials become easier to machine because their bearing and tensile strengths are lowered.Ceramic end mills can work effectively at these high temperatures and self generate the heat required to soften the machined material through ultra-high feeds and speeds.

Temperature

Proof strength

Tensile strength

Tens

ile S

treng

th,

Pro

of s

treng

th [M

Pa]

Tool life comparison with Inconel®718 (HRC45) Ceramic end mill

<Cutting condition>Tool : ø10xR1.0Depth of cut : ae=1.0 mm ap=7.0 mmOverhang : 20 mmCutting mode : Down cutCeramic : Dry (No air blow)Solid Carbide : Wet cutting

Cutting effi ciency 10 times

Before cutting After cutting (12 m)Edge Corner radius

Revolution :

19,098 min-1

Feed rate :

6,875 mm/min

Carbide end mill

6 fl ute

Revolution :

1,910 min-1

Feed rate :

688 mm/min

Tool life comparison-Inconel®718 (HRC 45)

<Cutting condition>Tool : ø12xR1.5Revolution : 18,568 min-1 (700 m/min)Feed rate : 6,684 mm/min (0.06 mm/tooth)Depth of cut : ae = 2.4 mm ap = 9.0 mm (Down cut)Overhang : 24 mmCutting mode : Dry (No air blow)

30 mBroken after 42 m machining

5 m

ConventionalConventional

Cutting length (m)

Broken after 15 m machining

Strong, negative flute and special rake edge withstands high temperatures and loads.

2.8 times longer tool

life

Application Example


Ultra-high-effi ciency performance

%°

%°

$°

$°

25

End mill (ø 6/R3) 4 flute Smart Miracle taper ball nose end mill (Non-stocked item)Work Material Inconel® 718Cutting Speed vc113 m/min (n6000 min-1)Feed fz0.06 mm/tooth (vf1440 mm/min)Depth of Cut ap0.4 mm, ae 0.5mmCoolant Emulsion

1.5 times

Finish Profile Milling


Application Examplea Achieved 1.5 times longer tool life in stable

machining without vibration.

Conventional


Wider chip pocket

Variable curve

Variable pitch

Key Point on Machininga When machining Ni-based alloys which have low thermal conductivity and

are subjected to work hardening, well-balanced cutting edge and superior coating grade are required.The latest SMART MIRACLE vibration control ball nose end mills have variable pitch geometry with newly designed radius-cutting-edges to reduce vibration.

Variable pitch

SMART MIRACLECoating

Newly designed radius cutting edges

reduce vibration

SMART MIRACLEVibration Controlball nose end mill

(TOOLS NEWS B197G)

SMART MIRACLE

0.50 1

26

Drill (Grade) MMS0610X3DB (DP7020)Work Material Inconel® 718Cutting Speed vc14 m/minFeed f0.06 mm/revHole Depth 15 mmCoolant Emulsion

VB: 0.21mm

DrillingMMS Drill

(TOOLS NEWS B180G)


Key Point on Machininga The key is how to cool the cutting edge when drilling Ni-based alloys.

It is possible to extend tool life greatly by using a solid carbide drill that employs TRI-Cooling through coolant technology with a high-pressure coolant supply.

Application Examplea 15 times longer tool life is achieved when applying high-

pressure internal coolant and TRI-cooling technology.

MMS: Internal coolant (7 MPa)

MWS: Internal coolant (1.5 MPa)

MWE: External coolant

15

1

1

50 10 15

“TRI-Cooling Technology”

Excellent cooling effect

15 times

Tool life (hole)

27

Key Point on Machininga Titanium-aluminium alloy has low thermal conductivity and tends to

concentrate heat on the cutting edge and moreover scratches can occur easily on the cutting surface when cutting Titanium-aluminium alloy. Therefore, it is important to remove heat on the cutting edge efficiently and to evacuate chips smoothly. The Smart Miracle end mills series with an optimum balance of sharpness and smoothness of the coating layer due to Mitsubishi original smoothening treatment enables stable cutting.

Application Examplea Smoothening treatment of the coating layer

reduces cutting resistance and improves tool life.End mill VQMHVRBD1200R100Work Material Titanium-aluminium AlloyCutting Speed vc60 m/min (n1592 min-1)Feed fz0.08 mm/tooth (vf509 mm/min)Depth of Cut ap 2 mm, ae 1 mmCoolant Emulsion

ENGINEWork Materials [Titanium-aluminium Alloy]

SMART MIRACLEENDMILL SERIES（TOOL NEWS B197J）

2 times

SMART MIRACLE

Conventional

Tool life (min)0 15 30 45 60



ZERO- μSURFACE

Superior vibration resistance

28

Holder H63TH-DCLNR-DX12Insert (Grade) CNMG120408-LS (MT9015)Work Material Ti-6Al-4VCutting Speed vc80, 120 m/minFeed f0.15mm/revDepth of Cut ap0.25 mmCoolant Emulsion

External and Face and Internal Turning HSK-T Tools

(TOOLS NEWS B134G)


ENGINEWork Materials [Titanium Alloy]

Key Point on Machininga Rough estimate of the tool life is 120 minutes at 80m/min, 60 minutes at 120m/

min, when finish-machining titanium-alloy. Non-coated grades are the first recommendation.

Application Example

Cutting Speedvc80 m/min

Cutting Speedvc120 m/min

300 60 90 120 150 180 210

LS Breaker

Tool life (min)

LS/MS/RSMT9015

(TOOLS NEWS B214G)

a By setting the correct cutting speed longer tool life can be achieved.

29

HSK-T Tools(TOOLS NEWS B134G)

Holder PSC63-DDJNRInsert (Grade) DNMG150412-MS (VP05RT)Work Material Maraging Steel (48-50HRC)Cutting Speed vc90 m/minFeed f0.23 mm/revDepth of Cut ap2 mmCoolant Emulsion

2 times

External and Face and Internal Turning

FJ/MS/GJVP05RT/VP10RT(TOOLS NEWS B036G)


ENGINEWork Materials [Maraging Steel]

Key Point on Machininga For rough machining of maraging steel shafts, generally cBN tool grades are

used. However for hard material ranges it is possible to use the VP05RT coated tool grade.

Application Examplea Compared to the conventional tool grade double

the tool life was achieved when using the VP05RT coated tool grade.

VP05RT

Conventional

50 10

MS Breaker

Tool life (min)

30

200 4000 600 800 1000 1200

External and FaceTurning



Tool wear minimization

JTHolder

a When machining heat resistance materials if heat generation can be prevented then tool life can be achieved.

Holder PSC50-DCJNRInsert (Grade) CNMG120408-MJ (US905)Work Material Inconel® 718Cutting Speed vc150 m/minFeed f0.1 mm/revDepth of Cut ap0.3 mmCoolant Emulsion

Application Examplea The example below shows the tool life increase when using the

external coolant system JT series. An increase of over 1.5 time and more can be obtained when compared to conventional external cooling.

JT discharge pressure: 20MPa

JT discharge pressure: 0.3MPa




External Coolant

Discharge Pressure and Tool Life Changes : Machined Length (m)

Wear standard = 0.2mm

31

Landing Gear

32

Holder VFX6-080A05A075RInsert (Grade) XNMU190912R-LS (MP9130)Work Material Ti-5Al-5Mo-5V-3CrCutting Speed vc40 m/min (n160 min-1)Feed fz0.1 mm/tooth (vf80 mm/min)Depth of Cut ap65 mm, ae5 mmCoolant Emulsion (8 MPa)

Rough Milling

VFX Series(TOOLS NEWS B182G)

Cutting force

LANDING GEARWork Materials [Titanium Alloy]

Key Point on Machininga When rough machining of titanium alloys problems such as chipping and

abnormal damage can occur if using tools with low rigidity. The VFX series offers a design that has high rigidity and also insert geometry that employs a convex cutting edge to improve cutting edge stability.

Application Examplea When used with a high pressure internal coolant

system tool life can be increased by up to 7 times compared to a conventional tool.

VFX

Conventional

300 60 90 120 150 180 210

Over 7 times

Arranging the inserts vertically

Convex curvecutting edge

V formation of the clamping face

Tool life (min)

33

Holder (Screw-in type) APX3000R254M12A35 SC25M12S125SWInsert (Grade) AOMT123620PEER-M (MP9120)Work Material Ti-6Al-4VCutting Speed vc40 m/min (n510 min-1)Feed fz0.08 mm/tooth (vf160 mm/min)Depth of Cut ap6 mm, ae25 mmCoolant Emulsion

Screw-in head

Carbide shank

Edge condition (85min.)


APX Series(TOOLS NEWS B055G)

Depth 80mm





problems relating to chipping and fracturing are common. The APX series inserts employ a curved cutting edge to reduce cutting resistance and rigid tool body with through coolant to achieve stable machining.

Application Examplea Even when used with long overhang applications

the combination of the screw-in head with a carbide shank stable machining was achieved.

High rigidity cutter body

Low cutting resistance insert

%°

%°

$°

$°

34

End mill VQ4SVBR0600Work Material Ti-10V-2Fe-3AlCutting Speed vc200 m/min (n5300 min-1)Feed vf1590 mm/minDepth of Cut ap1.0 mm, ae0.5 mmCoolant Emulsion


Wider chip pocket

Variable curve

Variable pitch



problems relating to vibration can easily occur. To prevent these problem the SMART MIRACLE vibration control end mill was developed. The series has irregular pitch and a newly developed radius geometry to overcome the problems related to vibration.

Application Examplea Stable machining was achieved, and tool life was

increased by 3 times due to the increase in the number of flutes.

VQ4SVB

VQ6SVB(increased number of teeth)

300 60 90

3 times

Tool life (min)

Variable pitch


Newly designed radius cutting edges

reduce vibration

SMART MIRACLEVibration Controlball nose end mill

(TOOLS NEWS B197G)

35

Head (Grade) IMX16C10HV160R10016 (EP7020)Holder IMX16-U16N056L110CWork Material Ti-6Al-4VCutting Speed vc150 m/min (n3000 min-1)Feed fz0.05 mm/tooth (vf1500 mm/min)Depth of Cut ap12 mm, ae0.5 mmCoolant Emulsion

No vibration

Chatter mark

ae 0.5mm

ap 12mm




problems relating to vibration can easily occur. To prevent these problem the iMX series also has a range of exchangeable heads that offer vibration resistance properties. Additionally chip evacuation can also be improved leading to stable machining.

Application Examplea Stable machining without vibration was achieved

resulting in an increase in tool life of up to 7 times.

iMX

Conventional

300 60 90

7 times

Tool life (min)

High Precision

High Rigidity



36

2D

øDHead (Grade) IMX20C4HV200R10040 (EP7020) Length of cutting edge 2D/ Non-stocked item

Holder IMX20-U20N070L130COverhang length 125 mmWork Material Ti-5Al-5Mo-5V-3CrCutting Speed vc38 m/min (n600 min-1)Feed fz0.04 mm/tooth (vf60 mm/min)Depth of Cut ap30 mm, ae5-20 mmCoolant Emulsion



Key Point on Machininga When finish machining of titanium alloys due to the type of chips generated

problems relating to vibration can easily occur. To prevent these problem the iMX series also has a range of exchangeable heads that offer vibration resistance properties. This ensures that even when using long overhang vibration can be minimized leading to stable machining.

Application Examplea Stable machining without vibration was achieve that resulted

in double the tool life.

iMX

Conventional

300 60 90

2 times

Tool life (min)

High Precision

High Rigidity



ae5-20 mm

ap30 mm

37

Drilling


Key Point on Machininga When machining titanium alloys due to the fact that the thermal conductivity is

low heat generated during machining localizes around the cutting edge. This results in welding problems and as such it is necessary to prevent heat generation and to remove the chips effectively. The MNS drill range is designed to increase the cooling effect and to discharge the chips via a unique flute geometry resulting is stable machining of titanium alloys.

Application Examplea Stable machining can be achieved due to effective

cooling and chip evacuation.

Outstanding sharpness and high

edge strength

Excellent cooling

performance

Improved chip removal

Drill (Grade) MNS0600X20DB (TF15)Work Material Ti-6Al-4VCutting Speed vc30 m/minFeed f0.06 mm/revHole Depth 120 mmCoolant Emulsion (3 MPa)

MNS Drill(TOOLS NEWS B135G)

38

MemoMemo

39

MemoMemo

EXP-16-E0162017.4.E(5A)

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AEROSPACE APPLICATIONS A613G - Mitsubishi Materials€¦ · AEROSPACE AIR FRAME 5 6 7 10 12 13 14 15 16 17 11 8 9 y CFRP y CFRP/AI y CFRP/Ti Tool Page y Precipitation Hardening Stainless